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WO1995016361A1 - Procede et appareil de preparation de pommes chips sans matieres grasses - Google Patents

Procede et appareil de preparation de pommes chips sans matieres grasses Download PDF

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Publication number
WO1995016361A1
WO1995016361A1 PCT/US1994/014193 US9414193W WO9516361A1 WO 1995016361 A1 WO1995016361 A1 WO 1995016361A1 US 9414193 W US9414193 W US 9414193W WO 9516361 A1 WO9516361 A1 WO 9516361A1
Authority
WO
WIPO (PCT)
Prior art keywords
slices
further characterized
fat
moisture content
cooking
Prior art date
Application number
PCT/US1994/014193
Other languages
English (en)
Inventor
Joey Petelle
Karen D. Stoesz
Lisa R. Williams
Original Assignee
Auburn Farms, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Auburn Farms, Inc. filed Critical Auburn Farms, Inc.
Priority to AU13053/95A priority Critical patent/AU1305395A/en
Publication of WO1995016361A1 publication Critical patent/WO1995016361A1/fr

Links

Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47J—KITCHEN EQUIPMENT; COFFEE MILLS; SPICE MILLS; APPARATUS FOR MAKING BEVERAGES
    • A47J37/00—Baking; Roasting; Grilling; Frying
    • A47J37/04—Roasting apparatus with movably-mounted food supports or with movable heating implements; Spits
    • A47J37/044—Roasting apparatus with movably-mounted food supports or with movable heating implements; Spits with conveyors moving in a horizontal or an inclined plane
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
    • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
    • A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
    • A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
    • A23L19/18—Roasted or fried products, e.g. snacks or chips
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
    • A23L5/00—Preparation or treatment of foods or foodstuffs, in general; Food or foodstuffs obtained thereby; Materials therefor
    • A23L5/10—General methods of cooking foods, e.g. by roasting or frying
    • A23L5/15—General methods of cooking foods, e.g. by roasting or frying using wave energy, irradiation, electrical means or magnetic fields, e.g. oven cooking or roasting using radiant dry heat
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/46—Dielectric heating
    • H05B6/60—Arrangements for continuous movement of material
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/46—Dielectric heating
    • H05B6/62—Apparatus for specific applications
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S426/00—Food or edible material: processes, compositions, and products
    • Y10S426/804—Low calorie, low sodium or hypoallergic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S99/00—Foods and beverages: apparatus
    • Y10S99/14—Induction heating

Definitions

  • the present invention relates generally to a method and apparatus of cooking foodstuffs, and, more particularly, to making fat-free potato chips by radiant heating, forced air heating and radio frequency wave heating.
  • Fats Edible fats and oils are organic compounds composed of three fatty acids attached to the glycerol molecule and are also known as triglycerides. Major types of fatty acids are saturated, polyunsaturated and monounsaturated.
  • the body needs a small amount of fats to carry fat soluble vitamins, to store energy, to cushion and protect vital organs, to insulate the body thermally, to give shape to the body and to regulate cellular metabolism.
  • Non-essential fatty acids are made by the body itself, but essential fatty acids must be obtained dietetically through the foods we eat. But, fatty foods are high in calories (9 calories per gram of fat) and too much dietetic fat is bad for many reasons.
  • Fats saturated with hydrogen cause the body to produce more cholesterol which has been linked to coronary disease known as atherosclerosis (plague build-up on artery walls).
  • Oil composed mainly of polyunsaturated fats, in large quantities may increase the risk of cancer, and high fat diets generally have been scientifically linked to breast, colon, pancreas and prostate cancer.
  • fatty foods cause obesity. One reason is that it takes less energy (fewer calories) to convert fat to stored fat cells in the body than, other foods, such as, foods high in carbohydrates. Fats and oils are now recommended by the U.S.
  • One tablespoon of a vegetable oil contains 14 grams of fat, 126 calories and 100% of the calories are from the fat. Most common oils and fats are high in saturated fats and/or polyunsaturated fats.
  • fat-free means the food product must have less than 0.5 grams of fat per serving. It is an object of the present invention to produce fat-free food products.
  • Potato Chips are a favorite snack food for all age groups.
  • Conventional potato chips are deep-fried in fat and are very high in calories.
  • the typical finished potato chip contains 30-45% fat by weight and less than 5% moisture by weight (unless otherwise indicated by the context, all percentages of contents listed herein are by weight).
  • a single one ounce (1 oz.) serving of any conventional potato chip contains about 10 grams of fat, 150 calories and 60% of the calories are from the fat. Not only is the deep-fried process difficult to control and inefficient, often resulting in overcooked chips, but also, the moisture and fat left in the product react together to shortly impart a rancid odor and flavor and loss of crispness which limits effective shelf life to about two weeks.
  • a further variation of a "no cooking oil” process was the batch process of Kloos (U.S. Patent 4,906,483) in which the microwave cooking step was employed early in the process to activate the release of starch while the potato slices were still immersed in water followed by a cold water rinse and final cooking in radiant heat until brown and crisp to produce a fat- free potato chip. ((c)). Cooking Between Dual Relieved Opposed Surfaces
  • Patent 4,919,965 which simultaneously final cooked the potato slices by compressing them between dual opposed heating surfaces which were 50% relieved driving the moisture into the voids in the cooking surfaces to produce a fat-free potato chip.
  • One aspect of the invention is in a continuous process for making a cooked foodstuff without using any cooking oil including initial cooking moist food slices wherein the improvement includes final cooking the food slices in a dielectric heater by subjecting the slices to long wavelength radio frequency electromagnetic waves in an even controlled heating environment until the final moisture content is reached.
  • a further feature of this aspect of the invention is initially cooking the slices in a three zone primary oven by first radiant heating the slices and then subjecting the slices to two successive stages of forced air heating to reduce the moisture content of the slices to near a final moisture content.
  • Further features of this aspect of the invention include beginning with raw potato slices, independently controlling the time duration in each of the three zones, simultaneously forcing the air into the top and bottom surfaces of the slices in the primary oven to a near final moisture content of about 15% by weight, independently controlling the time duration of the slices in the dielectric heater to a final moisture content of about 7% by weight using wavelengths of about 65.8 feet at a frequency of about 15 mhz, and allowing the slices to successively, increasingly pile up in the last two forced air stages and the dielectric heating stage whereby a palatable, crisp, fat-free potato chip is produced having the texture and mouthfeel of a deep-fat fried potato chip.
  • Another aspect of the invention is forming the slices by reciprocating means holding the potatoes against a fixed cutting blade.
  • the present invention has the advantages of providing a fully cooked fat-free potato chip, that is low in calories, has a long shelf life and is made by a process that is easy to control and is economical to operate while producing potato chips in commercial quantities.
  • FIGS. 1 , 2A and 3 are front elevation views of the continuous process of the present invention shown partially in schematic form and partially in section along the lines 2A-2A of Fig. 2.
  • Fig. 2 is a top plan view of the three zone primary oven of the present invention.
  • Figs. 1-3 show the preferred form of an apparatus for carrying out the process 10 of the present invention.
  • a fat-free potato chip can be produced without deep-fat frying the potato pieces and yet still maintain a pleasant look, mouth- feel, texture and taste of the finished product.
  • the improved process utilizes a three zone primary oven —having one radiant heat and two forced hot air stages for initial drying of the prepared monolayered potato slices to 7-15% moisture content— and then a dielectric long wavelength radio frequency oven for final drying of the chips to 7% moisture content.
  • a step-by-step description of the process 10 and associated apparatus follows in which the numbers next to each heading below correspond to numbered stations shown in Figs. 1-3.
  • the preferred starting materials are conventional chipping potatoes 11, such as, Kennebec or
  • the scrubber 13 is a conventional rotating drum with counter rotating rollers along the outside which are covered with a light abrasive that cleans the skins of the potatoes without removing the skin. If it is desired to remove the skins, the same piece of equipment can be equipped with more abrasive rollers to accomplish this step. The scrubbed potatoes then pass to the washing step.
  • the washer bin 14 is a vat of water that is used to rinse any remaining debris from the scrubbed potatoes.
  • the slicer is shown generally as 15 in Fig. 1 and slices the potatoes to a preferable uniform thickness of .7-.95 millimeters depending upon specific market desires. Uniform thickness is important to maintaining even oven temperatures and thorough even cooking of each slice.
  • the slicer 15 is a gravity fed, reciprocating bin 16 which cooperates with a stationary blade 17 to achieve a monolayering of the potato slices 24 on the moving conveyer belt 18.
  • the belt speed is adjusted fco achieve a preferential covering of about 85%-90% of the conveyer 18 with potato slices 24 ("product density").
  • the conveyer belt 18 is a 6 feet wide mesh screen sized to allow small chip pieces and slicing debris to fall through and be carried away by conventional means (not shown). The speed of the belt will vary with the quantity of throughput and the size of the potatoes and desired product density.
  • the monolayered slices 24 are spray washed.
  • the inclined, sprayer washer shown generally as 19 in Fig. 1 is a high pressured stream of water spraying the chips from equal angles 25 above and below the conveyer belt creating a squeegee action to remove excess starch and moisture.
  • spray washer 19 has multiple pairs of spray streams 20-23.
  • the angles 25 and force of the streams 20-23 are selected to achieve effective squeegee action without disturbing the monolayering and product density of the slices 24.
  • the incline of conveyer belt 18 further assists in the removal of the liquids and starch.
  • the potato slices 24 are now ready for cooking.
  • the primary oven 30 is a three zone cooking processor which includes a radiant oven 40 followed by two forced air convection ovens 50, 60.
  • the temperatures, air velocity and belt speeds are independently controllable in each phase to allow for maximum adaptability in accommodating the requirements of different varieties and throughputs of potatoes 11.
  • the following specifications are for an apparatus which has the output capacity at the end of the dielectric heating step 70 to continuously produce about 1000 lb./hr of finished potato product output.
  • the total input capacity of the primary oven 30 necessary to continuously provide the aforesaid output varies with the variation in the moisture content of the input potatoes 11.
  • the input capacity of primary oven 30 is about 4547.8 lbs./hr. in order to provide a final output after the dialectic heater of about 1004.9 lbs./hr.
  • the passage from the primary oven 30 to the dielectric heater 70 is enclosed to reduce the amount of lost heat during the transition between ovens.
  • the Radiant Zone As shown in Fig. 2A, monolayered slices 24 enter the input end of radiant zone 40 by dropping onto belt 42, which is 6 feet wide, without disturbing the monolayering.
  • the radiant oven 40 heats the chips from both the top and the bottom by radiant, gas, high intensity, ceramic heaters 41 operating at approximately 1600° F.
  • the length of this zone is about 15 ft.
  • the speed of the belt is about 30 ft. per minute.
  • the duration of slices 24 in this zone 40 is about 30 seconds at a product density of about 90% and a monolayered product depth of about .29 inches. This step brings the right amount of glucose to the surface of the chips 24.
  • Too little glucose will cause the chips 24 to dry out in the next steps creating a powder on the surface, a scaly appearance, reduced chip snap, tough texture and an unpalatable taste. Too much glucose removal will cause the chips 24 to have an extreme glazed appearance. The chips 24 next pass to the first forced air zone 50.
  • the First Forced Air Phase As shown in the embodiment of Fig. 2A, the monolayered chips 24 enter the first forced air zone 50 by dropping onto belt 51 which is 6 feet wide. Zone 50 is heated by gas burners 52, 62.
  • zone 50 the use of forced air is considered very important to the drying time of the potato chips 24.
  • the forced air actually is driven into the chips 24 to remove moisture at a rate which would take significantly longer in a solely convection or other standard oven.
  • Fans 53, 54 are shown mounted to the sides of the belt 51 in Fig. 2 but actually blow air into ducts 54a and 53a straddling the belt 51 and which exit directly onto the top and bottom, respectively, of the belt 51.
  • zone 50 hot dry, recirculated air is thus blown directly into the top and bottom surfaces of the chips 24 by zone 50 dry air recirculation fans 53, 54.
  • the hot air from fans 53, 54 is simultaneously driven into the top and bottom surface of the chips 24.
  • the outer layers of the chips 24 are also dried so that they do not stick together in the subsequent zones of the ovens 30, 70.
  • the air is heated to a temperature of about 410° F with about 4200 cubic ft./min. of air directed toward the top surface of the chips 24 and 6000 cubic ft./min. toward the bottom surface of the chips 24.
  • the removed moisture is vented to exhaust through the top exhaust fans 65, 66 of the oven 30.
  • a balance between exhaust and recirculation is achieved by trial and error based on observation and test of the throughput product.
  • the length of zone 50 is about 16 ft.
  • the belt 51 speed is about 20ft./min.
  • the zone duration is about 48 seconds.
  • the product density is about 135%. Because belt 51 is moving slower than belt 42, the product depth will vary during this phase due to the curling and pile-up effects of the chips 24.
  • the slices 24 then pass to the third zone 60 of oven 30.
  • fans 53, 54 are shown as side mounted with the exhaust fans 65, 66 at the top, other configurations are possible in both forced air zones 50, 60.
  • Zone 60 of the primary oven 30 by dropping onto belt 61 which is 6 feet wide.
  • Zone 60 is heated by gas burners 52, 62.
  • Zone 60 continues to dry the potato chips to near final moisture content by forcing dry hot air into the top surfaces and bottom surfaces of the chips 24 using side mounted recirculating fans 63, 64 shown in Fig. 2 which blow into bottom duct 63a and top duct 64a in the same manner as was done in zone 50.
  • the air is heated to a temperature of about 350° F with about 4200 cubic ft./min. of air directed at the top surfaces and about 6000 cubic ft/min at the bottom surfaces of the chips.
  • the moisture is vented through the top of the oven by exhaust fans 65, 66 with balance achieved between exhaust and recirculation as was done in zone 50.
  • the length of this zone is longer, i.e., about 29 ft.
  • the belt 61 speed is about 5.8 ft./min.
  • the phase duration is about 5 minutes (300 seconds).
  • the product density is about 465%.
  • This final phase of the primary oven 30 dries the potato chips 24 to approximately 15% moisture content.
  • the chips 24 then pass to the final cooking stage in dielectric oven 70. Although it is possible to dry the chips in zone 60 to the final desired moisture content target of approximately 7%, it creates an unacceptable "sawdust taste". More than 15% moisture content will put additional strains on the production capacities of the dielectric heater 70 in the next step.
  • the chips 24 enter the dielectric oven or drier 70 by dropping onto belt 71 which is about 6 feet wide.
  • the dielectric oven 70 uses long wavelength, radio frequency, electro-magnetic waves of about sixty-six (66) feet wavelength to create a controlled even heat which heats the chips 24 from deep inside the product in order to remove the remaining moisture to the desired 7% final moisture level. Most dielectric heating is done at radio frequencies of 10-100 MHz.
  • the preferred operating frequency range of the dielectric oven of the present invention is about 10-20 mhz which is in the high frequency range.
  • Conventional microwave technology such as is used in common home microwaves, uses a wavelength of 1.00 feet to .40 feet for operating frequencies of 915-2450 mhz, respectively, and creates an uneven poorly controlled heat which is unacceptable for the final heating stage of the continuous process of the present invention.
  • the dielectric oven 70 uses two tandem mounted 20 kilowatt parallel plate (electrodes) high frequency fields schematically shown in Fig. 3 as generator 74 and parallel electrode pairs 72 -72a and, 73 -73a, one following the other.
  • the belt 71 speed is variable and is selected so that the depth of the potato slices is allowed to pile up until it is approximately 7 inches, about double the depth of the product 24 in the second forced air zone 60 of primary oven 30. This bed depth in oven 70 optimizes the moisture removal capability of dielectric heater 70.
  • the time duration of the product in dielectric heater 70 is also variable depending upon the desired moisture content of the chips 24 incoming to heater 70. 10. THE SEASONING UNIT As shown in Fig. 3, the seasoning unit 80 is barrel shaped with two distinct phases of operation. The first stage has sprayers 81 which add "Tack" for adhering the dry seasonings added in the second stage. The tack may be maltodextrin, gum arabic, edible oil (up to the FDA regulated limit for fat-free) or other similar substances. Liquid flavor extracts and brine salt may be added at this phase. Fat-free substitutes simulating fat mouthfeel, if available, may be added.
  • the second phase has an auger 82 which applies dry seasoning to the potato chips including salt and other seasonings such as Bar-B-Que, Sour Cream Onion and the like. Depending on plant layout and temperate zone in which it is located, a heat tunnel may be required to dry or cure the seasoning mix to the chips 24.
  • Belt 83 may be operated at any convenient speed to accommodate the throughput of the line and bag and carton the finished chips 24.
  • a conventional machine folds and molds plastic film into bags 85 which are placed on conveyer belt 84.
  • the conveyer 83 drops measured amounts of the finished chips 24 into the plastic bags 85.
  • the machine (not shown) seals the plastic bags 85.
  • CASE PACKING As shown in Fig. 3, once the chips 24 are bagged they are placed into boxes 86. These boxes are then moved to the warehousing area. 13. WAREHOUSE
  • the finished chips 24 are produced in accordance with anticipated orders. However since the chips have no oil and a low moisture content, they do not readily become rancid or lose their crispness. Chips 24 have a storage/shelf life of 6 months or more.
  • the process 10 has been described with respect to making a potato chip snack food product 24. However, with minor adjustments the process is equally capable of making other snack foods, including taco/tortilla chips, formed potato chips, potato sticks, puffs and crisps, non-potato chips and puffs and similar snack food products.

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  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Health & Medical Sciences (AREA)
  • Nutrition Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Preparation Of Fruits And Vegetables (AREA)

Abstract

L'invention concerne un procédé continu de fabrication de pommes chips sans matières grasses, dans lequel aucune huile de cuisson n'est utilisée. Des pommes de terre spécialement utilisées pour les chips sont préparées, tranchées, déposées en continu en une seule couche sur un transporteur (18) et raclées de manière à enlever l'excès d'amidon et l'humidité. Les tranches (24) sont d'abord cuites sur des convoyeurs commandés séparément (42, 51, 61) dans un four principal à trois zones (30) dans lequel elles sont d'abord chauffées par chaleur radiante et soumises à deux étages de chauffage par convection d'air forcé consistant à envoyer simultanément de l'air sur les deux surfaces des tranches tandis que la teneur en humidité est réduite à 15 %. Pour finir, les tranches sont cuites dans un dispositif de chauffage diélectrique (70) dans lequel une chaleur uniformément répartie est appliquée dans deux zones de séchage associées dans lesquelles les tranches de pommes de terre sont exposées à des ondes radioélectriques longues envoyées par deux émetteurs 20 kW de manière à réduire la teneur en humidité des tranches finies à 7 %. Les pommes chips finies, une fois assaisonnées et emballées, présentent la texture, l'aspect et le goût de pommes chips frites.
PCT/US1994/014193 1993-12-16 1994-12-13 Procede et appareil de preparation de pommes chips sans matieres grasses WO1995016361A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU13053/95A AU1305395A (en) 1993-12-16 1994-12-13 Method and apparatus of making fat-free potato chips

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US08/168,640 US5470600A (en) 1993-12-16 1993-12-16 Method of making fat free potato chips
US08/168,640 1993-12-16

Publications (1)

Publication Number Publication Date
WO1995016361A1 true WO1995016361A1 (fr) 1995-06-22

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ID=22612340

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1994/014193 WO1995016361A1 (fr) 1993-12-16 1994-12-13 Procede et appareil de preparation de pommes chips sans matieres grasses

Country Status (4)

Country Link
US (2) US5470600A (fr)
AU (1) AU1305395A (fr)
WO (1) WO1995016361A1 (fr)
ZA (1) ZA949978B (fr)

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US9521857B2 (en) 2011-01-31 2016-12-20 Frito-Lay Trading Company Gmbh De-oiling apparatus and method in manufacture of low oil potato chips

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CN108289495A (zh) 2015-08-03 2018-07-17 吉米安仕有限责任公司 用于向食品中受控地引入油的方法
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US5470600A (en) 1995-11-28
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US5560287A (en) 1996-10-01

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